Mechanical & Thermal Engineer
Engineers in this role design and optimize mechanical systems, thermal management solutions, and structural components for AI hardware infrastructure and advanced autonomous systems. They work hands-on across the full product lifecycle—from concept and CAD modeling through testing and production—solving complex engineering challenges like cooling strategies for high-density compute clusters, structural integrity under extreme operating conditions, and integration of electronics into ruggedized platforms. These roles typically sit within specialized engineering teams at AI and defense-focused companies, collaborating closely with thermal, electrical, and systems engineers to deliver mission-critical hardware that meets demanding performance and reliability standards.
Skills
What companies are looking for in this role.
Designing and optimizing mechanical structures and assemblies for performance, mass, and reliability requirements
Creating detailed 3D CAD models, assemblies, and production-ready technical drawings with GD&T documentation
Managing the full hardware lifecycle from concept development through prototyping, qualification, and field deployment
Performing structural analysis, finite element analysis, and thermal simulations to validate design integrity
Integrating mechanical subsystems with electrical, thermal, and software components across product platforms
Collaborating with cross-functional teams including manufacturing, quality, supply chain, and program management
Selecting materials and manufacturing processes appropriate for production scalability and cost efficiency
Developing ruggedized hardware designs that withstand shock, vibration, thermal, and environmental constraints
Owning mechanical design responsibility for subsystems or product areas from architecture through production
Performing hands-on prototyping and fabrication to validate design concepts and resolve technical challenges
Designing for manufacturability and optimizing designs for volume production and supply chain efficiency
Designing cooling systems, HVAC infrastructure, and thermal management solutions for data centers and high-performance computing environments
Designing and optimizing fluid systems including pumping, flow control, heat exchangers, and chemical treatment
Conducting technical due diligence and feasibility assessments for complex mechanical infrastructure projects
Designing optomechanical assemblies including flexure mounts, kinematic mounts, and precision optical housings
Developing athermalized optical designs to maintain alignment and performance across operational temperature ranges
Designing modular and prefabricated mechanical systems to accelerate construction and deployment timelines
Integrating robotics and automation systems into lab workflows and manufacturing processes
Automating testing procedures and analyzing hardware performance data using programming and data tools
Communicating complex technical information clearly to cross-disciplinary teams and stakeholders
Translating vague early-stage requirements into clear specifications and build-ready hardware solutions
Coordinating with site contractors, subcontractors, and suppliers on project delivery and standards compliance
Rapidly troubleshooting design issues and implementing field fixes under time constraints
Leading and mentoring engineering teams while maintaining technical credibility as an individual contributor
Managing engineering workqueues, resource allocation, and project schedules to meet delivery timelines
Engaging directly with end-users and subject matter experts to understand operational requirements and constraints
Managing engineering change orders and lifecycle updates throughout product development and production
Technology
The tools and technologies that define this role.
Open Jobs
106 open Mechanical & Thermal Engineer jobs across 22 companies.
Other Physical Systems roles
Engineers designing and building electronic hardware, electrical systems, power electronics and signal chains. Covers circuit design, PCB layout, power delivery, RF/antenna design and signal integrity.
Engineers working on integrated circuit and system-on-chip design, including RTL design, physical design, silicon verification, ASIC/FPGA development, SoC architecture, and advanced packaging.
Engineers writing software that runs directly on hardware — firmware, embedded systems, RTOS, device drivers, microcontroller programming, and board support packages.
Engineers building physical robotic systems — manipulation, locomotion, motion planning, controls, perception for physical interaction, and autonomous navigation. Covers the full robotics stack from hardware integration through control software. Distinguished from Simulation Engineer (research_science) which builds virtual environments for training AI.
Engineers ensuring the safety of physical systems through functional safety analysis, hazard assessment, system safety engineering, and verification & validation of safety-critical systems.